Tool for configuring and managing a process control network including the use of spatial information

ABSTRACT

The present invention is directed to a tool which includes spatial information for configuring and managing a process control system which conforms to a standard protocol. Such a tool advantageously allows the efficient design and use of a process control system while ensuring that the physical characteristics of the system conform to the standard. In addition, the tool provides for more efficient diagnostics, on-line debugging, alarm monitoring and device maintenance.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuing application to the U.S. patentapplication Ser. No. 09/488,335, filed on Jan. 20, 2000 now U.S. Pat.No. 6,772,017B, and entitled “Tool For Configuring and Managing aProcess Control Network Including the Use of Spatial Information.”Accordingly, this application relates to and incorporates herein byreference as fully set forth herein the U.S. patent application Ser. No.09/488,335, filed on Jan. 20, 2000 now U.S. Pat. No. 6,772,017B1 andentitled “Tool For Configuring and Managing a Process Control NetworkIncluding the Use of Spatial Information.”

FIELD OF THE DISCLOSURE

The present invention relates generally to process control networks andmore particularly to configuring and managing process control networks.

DESCRIPTION OF THE RELATED ART

Large processes such as chemical, petroleum and other manufacturing andrefining processes include numerous field devices disposed at variouslocations within a facility to measure and control process parameterswhich thereby effect control of

the process. These devices may be, for example, sensors such astemperature, pressure and flow rate sensors as well as control elementssuch as valves and switches. Historically, the process control industryused manual operations such as manually reading level and pressuregauges, turning valve wheels, etc., to operate the measurement andcontrol field devices within a process.

Presently, control of the process is often implemented usingmicroprocessor-based controllers, computers or workstations whichmonitor the process by sending and receiving commands and data tohardware devices to control either a particular aspect of the process orthe entire process as a whole. The specific process control functionsthat are implemented by software programs in these microprocessors,computers or workstations may be individually designed, modified orchanged through programming while requiring no modifications to thehardware. For example, an engineer might cause a program to be writtento have the controller read a fluid level from a level sensor in a tank,compare the tank level with a predetermined desired level, and then openor close a feed valve based on whether the read level was lower orhigher than the predetermined, desired level. The parameters are easilychanged by displaying a selected view of the process and then bymodifying the program using the selected view. The engineer typicallywould change parameters by displaying and modifying an engineer's viewof the process.

The controller, computer or workstation stores and implements acentralized and, frequently, complex control scheme to effectmeasurement and control of process parameters according to an overallcontrol scheme. Usually, however, the control scheme implemented isproprietary to the field device manufacturer, thus making the processcontrol system difficult and expensive to expand, upgrade, reprogramand/or service because the field device provider must become involved inan integral way to perform any of these activities. Furthermore, theequipment that can be used or interconnected may be limited due to theproprietary nature of the field device and the situation where theprovider may not support certain devices or functions of devicesmanufactured by other vendors.

To overcome some of the problems inherent in the use of proprietaryfield devices, the process control industry has developed a number ofstandard, open communication protocols including, for example, theHART®, DE, PROFIBUS®, WORLDFIP®, LONWORKS®, Device-Net®, and CANprotocols. These standard protocols enable field devices made bydifferent manufacturers to be used together within the same processcontrol environment. In theory, any field device that conforms to one ofthese protocols can be used within a process to communicate with and tobe controlled by a process control system or other controller thatsupports the protocol, even if the field devices are made by differentmanufacturers.

To implement control functions, each process control device includes amicroprocessor having the capability to perform one or more basiccontrol functions as well as the ability to communicate with otherprocess control devices using a standard and open protocol. In thismanner, field devices made by different engineer and the microprocessorbased controller or computer performing the process control function.

Systems that perform, monitor, control, and feed back functions inprocess control environments are typically implemented by softwarewritten in high-level computer programming languages such as Basic,Fortran or C and executed on a computer or controller. These high-levellanguages, although effective for process control programming, are notusually used or understood by process engineers, maintenance engineers,control engineers, operators and supervisors. Higher level graphicaldisplay languages have been developed for such personnel, such ascontinuous function block and ladder logic. Thus each of the engineers,maintenance personnel, operators, lab personnel and the like, require agraphical view of the elements of the process control system thatenables them to view the system in terms relevant to theirresponsibilities.

The graphical view of the elements of the process control system areprovided without correlation to the spatial layout of the facility andonly show logical connections of the devices and functions. For example,a process control program might be written in Fortran and require twoinputs, calculate the average of the inputs and produce an output valueequal to the average of the two inputs. This program could be termed theAVERAGE function and may be invoked and referenced through a graphicaldisplay for the control engineers. A typical graphical display mayconsist of a rectangular block having two inputs, one output, and alabel designating the block as AVERAGE. A different program may be usedto create the graphical representation of this same function for anoperator to view the average value. Before the system is delivered tothe customer, these software programs are placed into a library ofpredefined user selectable features. The programs are identified byfunction blocks. A user may then invoke a function and select thepredefined graphical representations illustrated by rectangular boxes tocreate different views for the operator, engineer, etc. by selecting oneof a plurality of function blocks from the library for use in defining aprocess control solution logically rather than having to develop acompletely new program in Fortran, for example, manufacturers can beinterconnected within a process control loop to communicate with oneanother and to perform one or more process control functions or controlloops. Another example of an open communication protocol that allowsdevices made by different manufacturers to interoperate and communicatewith one another via a standard bus to effect decentralized controlwithin a process is the FOUNDATION Fieldbus protocol (hereinafter the“Fieldbus protocol”) by the Fieldbus Foundation. The Fieldbus protocolis an all digital, two-wire loop protocol.

When using these protocols, a challenge associated with designing theprocess control system or network relates to the actual physical layoutand interconnection of the various process control devices.Specifically, each of these protocols sets forth constraints of valuesfor the physical characteristics within which a process control systemmust operate to conform to the standard. These constraints include thevoltage drop across communication sections, the spur length, the overallcable length, the total current draw and the total number of processcontrol devices on a particular hub. The physical location of vessels,pipes, pumps, motors and valves as well as controllers and operatorstations also set forth constraints that must be taken into account whenconfiguring the process control system or network. The interrelationshipof these constraints are important and variable based upon the values ofthe constraints. Once the process control system or network isconfigured and in use, the managing of the system can be cumbersome dueto the complexity of most refining and manufacturing facilities.

In addition to executing control processes, software programs alsomonitor and display a view of the processes, providing feedback in theform of an operator's display or view regarding the status of particularprocesses. The monitoring software programs also signal an alarm when aproblem occurs. Some programs display instructions or suggestions to anoperator when a problem occurs. The operator who is responsible for thecontrol process needs to view the process from his point of view andcorrect the problem quickly. A display or console is typically providedas the interface between the microprocessor based controller or computerperforming the process control function and the operator and alsobetween the programmer or

A group of standardized functions, each designated by an associatedfunction block, may be stored in a control library. A designer equippedwith such a library can design process control solutions by logicallyinterconnecting, on a computer display screen, various functions orelements selected with the function blocks represented by rectangularboxes to perform particular tasks. The microprocessor or computerassociates each of the functions or elements defined by the functionblocks with predefined templates stored in the library and relates eachof the program functions or elements to each other according to theinterconnections desired by the designer. A designer designs an entireprocess control program using logical views of predefined functionswithout ever correlating the design to the spatial dimensions of therefining or manufacturing facility.

One challenge associated with the graphical views provided is that onlylogical connections are shown. Presently, the physical layout of thefacility is not correlated to the configuration of the process controlsystem and cannot be referenced during the managing of the system. Whenconfiguring the process control system, spatial information must bemanually measured and entered into the tool. When managing the processcontrol system, the physical location of devices and controllers must bemanually determined, often increasing the amount of time required tocorrect a problem or mange the process control system.

What is needed is a method of configuring a process control system thattakes into account the physical layout of the facility as well as allowsfor operators of the system to quickly access the spatial location ofprocess control devices and controllers.

SUMMARY OF THE DISCLOSURE

The present invention is directed to using spatial information of afacility for configuring and managing a process control system which isincluded within the facility. The process control system may conform toa standard protocol. Such a system advantageously allows the efficientdesign and use of a process control system while ensuring that thephysical characteristics of the system conform to the standard. Inaddition, such a system also advantageously provides for more efficientdiagnostics, on-line debugging, alarm managing and device maintenance.

The tool may optionally provide automatic generation of the layout ofthe process control network applied to the spatial layout of thefacility.

In another embodiment, the tool is used to analyze the layout of theprocess control network applied to the physical layout of the facilityto assure that the layout of the network conforms to the criteria of astandard protocol, such as the Fieldbus protocol.

The tool may optionally provide blinking device representations toindicate active alarms in the network.

In another embodiment, the process control network is configured usinglogical connections first, and then at a later time the configuration isapplied to the spatial layout of the facility and used for managing theprocess control network using the spatial information applied to thenetwork layout.

Other applications of the present disclosure will become apparent tothose skilled in the art when the following description of the best modecontemplated for practicing the invention is read in conjunction withthe accompanying drawings.

DETAILED DESCRIPTION OF THE DRAWINGS

The present invention may be better understood, and its numerousobjects, features, and advantages made apparent to those skilled in theart by referencing the accompanying drawings.

FIG. 1 a is a schematic block diagram of a process control systemshowing a workstation including a tool in accordance with a generalizedembodiment of the present invention which furnishes a spatialconfiguring and managing capability.

FIG. 1 b is a block diagram of the controller/multiplexer and processportion of the process control system shown in FIG. 1 a.

FIG. 2 is a schematic block diagram showing the process controlenvironment in a configuration implementation and a management orrun-time implementation.

FIG. 3 is a flow chart illustrating the operation of a tool inaccordance with the present invention.

FIG. 4 is a screen presentation of the configuration portion of the toolshowing logical connections between functions and devices of a processcontrol system.

FIGS. 5A–5C are views of the spatial portion screen presentation showingphysical connections between functions and devices of a process controlsystem and their relative positions in the spatial layout of thefacility.

DETAILED DESCRIPTION OF THE DISCLOSURE

A process control environment 100 is shown in FIG. 1 a and illustrates acontrol environment for implementing a digital control system, processcontroller or the like. The process control environment 100 includes anoperator workstation 102, a lab workstation 104, and an engineeringworkstation 106 electrically interconnected by a local area network(“LAN”) 108, or other known communication link, for transferring andreceiving data and control signals among the various workstations and aplurality of controller/multiplexers 110. Workstations 102, 104, and 106are, for example, computers which conform to the IBM compatiblearchitecture. The workstations 102, 104, and 106 are shown connected bythe LAN 108 to a plurality of the controller/multiplexers 110 thatelectrically interface between the workstations and a plurality ofprocesses 112. In multiple various embodiments, the LAN 108 includes asingle workstation connected directly to a controller/multiplexer 110 oralternatively includes a plurality of workstations, for example threeworkstations 102, 104, and 106, and many controller/multiplexers 110depending upon the purposes and requirements of the process controlenvironment 100. In some embodiments, a single processcontroller/multiplexer 110 controls several different processes 112 oralternatively controls a portion of a single process.

In the process control environment 100, a process control strategy isdeveloped by creating a software control solution on the engineeringworkstation 106, for example, and transferring the solution via the LAN108 to the operator workstation 102, lab workstation 104, and tocontroller/multiplexer 110 for execution. The operator workstation 102supplies interface displays to the control/monitor strategy implementedin the controller/multiplexer 110 and communicates to one or more of thecontroller/multiplexers 110 to view the processes 112 and change controlattribute values according to the requirements of the designed solution.The processes 112 are formed from one or more field devices, which maybe smart field devices or conventional (non-smart) field devices.

In addition, the operator workstation 102 communicates visual and audiofeedback to the operator regarding the status and conditions of thecontrolled processes 112. The engineering workstation 106 includes aprocessor 116, and a display 115 and one or more input/output oruser-interface device 118 such as a keyboard, light pen and the like.The workstation also includes a memory 117, which includes both volatileand non-volatile memory. The memory 117 includes a control program thatexecutes on the processor 116 to implement control operations andfunctions of the process control environment 100. The memory 117 alsoincludes a configuring and managing tool 120 (also referred to as acontrol studio tool). The operator workstation 102, and otherworkstations (not shown) within the process control environment 100include at least one central processing unit (not shown) which iselectrically connected to a display (not shown) and a user-interfacedevice (not shown) to allow interaction between a user and theprocessor.

Tool 120 is used for configuring of the process control network and toensure that the process control network corresponds to a desiredstandard protocol, e.g., the Fieldbus protocol. Tool 120 may also beused during the managing of the process control network to provide formore efficient trouble shooting and maintenance. Tool 120 is preferablysoftware that is stored in memory 117, but may be contained on computerreadable media, and is executed by processor 116 of engineeringworkstation 106. The computer readable media may be a floppy disc, aCDROM or any other type of media on which software may be stored. Thetool 120 enables screen presentations that are presented on display 115of engineering workstation 106 which may show only the logicalconnection of process 112 or may include physical connectionsincorporating the spatial characteristics of the refining ormanufacturing facility's layout.

While the tool of the present invention is described in detail inconjunction with a process control system that uses Fieldbus devices, itshould be noted that the tool of the present invention can be used withprocess control systems that include other types of field devices andcommunication protocols, including protocols that rely on other thantwo-wire buses and protocols that support only analog or both analog anddigital communications. Thus, for example, the tool of the presentinvention can be used in any process control system that communicatesusing the HART, PROFIBUS, etc. communication protocols or any othercommunication protocols that now exist or that may be developed in thefuture.

A general description of the Fieldbus protocol, field devices configuredaccording to this protocol, the way in which communication occurs in aprocess control environment that implements the Fieldbus protocol, andexample constraints of values that are required under the Fieldbusprotocol will be provided. However, it should be understood that theFieldbus protocol is known in the art and is described in detail innumerous articles, brochures and specifications published, distributedand available from, among others, the Fieldbus Foundation, anot-for-profit organization located in Austin, Tex. In particular, theFieldbus protocol including constraints of values that are requiredunder the Fieldbus protocol is described in detail in “Wiring andInstallation 31.25 Kbits/sec. Voltage Mode Wire Medium ApplicationGuide” Foundation Fieldbus, 1996.

Generally, the Fieldbus protocol is a digital, serial, two-waycommunication protocol that provides a standardized physical interfaceto a two-wire loop or bus interconnecting process control equipment suchas sensors, actuators, controllers, valves, etc. included within aninstrumentation or process control environment. The Fieldbus protocolprovides, in effect, a local area network for field instruments (fielddevices) within a process, which enables these devices to performcontrol functions at locations distributed throughout a process and tocommunicate with one another before and after the performance of thesecontrol functions to implement an overall control strategy. Because theFieldbus protocol enables control functions to be distributed throughouta process control network, the protocol reduces the complexity of, orentirely eliminates the necessity of, the centralized processcontroller. However, the distributed nature of the system addscomplexity when managing the system and determining the physicallocation of problem devices when trouble shooting and managing thesystem.

The Fieldbus protocol allows for managing of the field devices andoverall process control system by providing communication via devicedescriptions and function blocks. Field devices are field instrumentssuch as transmitters and valves with processors that monitor deviceperformance and state. A device description is similar to a driver forthe device. For field devices, the device description includes thecalibration procedures, parameter procedures, and other informationrequired by the control system to communicate with the field device.Field devices notify the control system of standard operating parametersand are self diagnosing and capable of reporting device problems such asinstrument out of calibration to the control system. Each field devicehas a unique physical device tag and a corresponding network address.

For managing field devices, many types of communication is available,including: obtaining port and communication statistics, obtaining statusof the field device, viewing and changing resource configuration andparameters, initiating master reset or self test of the field device,displaying status of the sensors and changing the sensor upper, lowerand zero trim. By providing spatial information with the managingcommunications listed above, the managing features of the processcontrol system are more efficient and easier to use.

Referring to FIG. 1 b, the controller/multiplexer and process portion ofthe process control network 100 of FIG. 1 a conforming to the Fieldbusprotocol is shown. The network includes a controller/multiplexer 110which is coupled to one or more process 112 comprised of a plurality offield devices via a bus 142. The bus 142 includes a plurality ofsections or segments having corresponding lengths as well as othercharacteristics. The bus 142 also may include one or more junction boxes144 (JB1, JB2, JB3), which are often referred to as “bricks”. Eachjunction box 144 may be coupled to one or more held bus devices 146 tothe bus 142. Controller/multiplexer 110 is also coupled to at least onepower supply 148. The network illustrated in FIG. 1 b is illustrativeonly, there being many other ways in which a process control network maybe configured using the Fieldbus protocol.

Process control network 100 includes a number of spatial characteristicssuch as the spur length of a particular communication section, theoverall length of the bus, the total number of process control devicescoupled to a particular junction box, and the physical location of thecontrollers and devices with respect to the layout of the refining ormanufacturing facility. These spatial characteristics may beautomatically measured and calculated during the configuration of thesystem, using the spatial information regarding the physical layout ofthe facility. Process control network 100 also includes a number ofnon-spatial characteristics such as the voltage drop acrosscommunication sections, the total current draw of a segment, and thetypes of devices in the system. These non-spatial characteristics areprovided by the user when configuring the system. Tool 120 analyzesthese characteristics to determine whether the process control networkcorresponds to the desired standard protocol.

Once the configuration of the process control system has been completed,tool 120, including the spatial layout of the system in the facility,can be used for managing of the process control system using any of theworkstations 102, 104 or 106. The function of managing the processcontrol system includes such functions as diagnostics, on-linedebugging, alarm monitoring and device maintenance. During diagnosticsand alarm monitoring, when a valve or other device fails, the device'srepresentation on the screen of the display device may blink in thespatial view of the facility and be easily found. The device's tag nameas well as the spatial location of the device can be used to identifythe valve or other device. During on-line debugging, the values of theconnectors and attributes in the function blocks can be shown in thespatial view of the facility allowing the user to more easily ascertainthe current conditions of the system. During device maintenance, byselecting a device in the spatial view, current conditions andinformation about the device can be obtained, such as the current flowrate or latest maintenance records.

The process control environment 100 exists in a configuration model orconfiguration implementation 210 and a managing or run-time model orimplementation 220 shown in FIG. 2. In the configuration implementation210, the component devices, objects, interconnections andinterrelationships within the process control environment 100 aredefined and related to the spatial information regarding the physicallayout of the facility. In the run-time implementation 220, operationsof the various component devices, objects, interconnections andinterrelationships are performed. The configuration implementation 210and the run-time implementation 220 are interconnected through a ASCIIbased download language. The download language creates system objectsaccording to definitions supplied by a user and creates instances fromthe supplied definitions. In addition to downloading definitions, thedownload language also uploads instances and instance values. Theconfiguration implementation 210 is activated to execute in the run-timeimplementation 220 using an installation procedure.

The process control environment 100 includes multiple subsystems withseveral of the subsystems having both a configuration and a run-timeimplementation. For example, a process graphic subsystem 230 suppliesuser-defined views and operator interfacing to the architecture of theprocess control environment 100. The process graphic subsystem 230 has aprocess graphic editor 232, a part of the configuration implementation210, and a process graphic viewer 234, a portion of the run-timeimplementation 220. The process graphic editor 232 is connected to theprocess graphic viewer 234 by an intersubsystem interface 236 in thedownload language. The process control environment 100 also includes acontrol subsystem 240 which configures and installs control modules andequipment modules in a definition and module editor 242 and whichexecutes the control modules and the equipment modules in a run-timecontroller 244. The definition and module editor 242 operates within theconfiguration implementation 210 and the run-time controller 244operates within the run-time implementation 220 to supply continuous andsequencing control functions. The definition and module editor 242 isconnected to the run-time controller 244 by an intersubsystem interface246 in the download language. The multiple subsystems are interconnectedby a subsystem interface 250.

The configuration implementation 210 and the run-time implementation 220interface to a master database 260 to support access to common datastructures. Various local (non-master) databases 262 interface to themaster database 260, for example, to transfer configuration data fromthe master database 260 to the local databases 262 as directed by auser. Part of the master database 260 is a persistent database 270. Thepersistent database 270 is an object which transcends time so that thedatabase continues to exist after the creator of the database no longerexists and transcends space so that the database is removable to anaddress space that is different from the address space at which thedatabase was created. The entire configuration implementation 210 isstored in the persistent database 270.

The run-time implementation 220 interfaces to the persistent database270 and to local databases 262 to access data structures formed by theconfiguration implementation 210. In particular, the run-timeimplementation 220 fetches selected equipment modules, displays and thelike from the local databases 262 and the persistent database 270. Therun-time implementation 220 interfaces to other subsystems to installdefinitions, thereby installing objects that are used to createinstances, when the definitions do not yet exist, instantiating run-timeinstances, and transferring information from various source todestination objects.

Referring to FIG. 3, a flow diagram illustrating the operation of thetool 120 is shown. The different steps of the tool 120 operate accordingto a “Wizard” functionality as is present in various programs which rununder a WINDOWS™ operating system. After each step is completed, theuser then transfers' to the next step by actuating a “NEXT” button orthe like. If the user does not want to proceed then the user can exitthe tool by actuating an “EXIT” button or the like.

In Step 310, the user provides the tool with information relating to thenon-spatial characteristics of the process control network. Thisinformation includes such things as information about the customer, thedevices used, calibration data, tag names, cable type, power supplycharacteristics and card, segment, and junction configurationinformation. The customer information may include the name of thecustomer, the name of the company, the location of the facility at whichthe network is located, the name of the representative providing thetool and the name of a contact for that representative. The cardconfiguration information may provide the user with information aboutthe type of cards used and operations which are used for analyzing theprocess control network 100. The segment configuration information mayinclude the voltage of the power supply, the cable type (includinginformation about the gauge of the wire that is used within the cable aswell as other characteristics of the cable). The junction configurationinformation may include information regarding devices that are coupledto the junction and how the coupling to the junction is configured,including spur cable type, and the type of instrument that is coupled tothe junction box. In the preferred embodiment, the instrument is adevice that conforms to the Fieldbus protocol. The user may optionallyassign a tag identification to the instrument.

To configure a card, a user selects a controller card from a list ofavailable controller cards. After the card is selected, then thepertinent information for the selected controller card may be providedto the tool. Essentially, by selecting a controller card, the userconfigures a segment of the network. In the preferred embodiment, eachcontroller card may control two segments; however, depending upon thecontroller card more of less segments may be controlled by a controllercard. While the segments are being configured, the user may access asummary of the information that has been provided to the tool 120.

In Step 320, the user provides spatial information regarding thefacility to the tool. In particular, the physical layout of the facilityincluding floor plan size, instrument type, size, and location, and wireframe representations are provided. This information may be provided tothe tool by the user or imported from another tool such as a 3D Toolkit,for example, Open Inventor from TGS.

In Step 330, function blocks are created and activated. In the Fieldbusprotocol, function blocks provide the control of system behavior and caninclude such functions as calibration procedures, parameter procedures,and communication procedures. Each Fieldbus device may have severalfunction blocks. The arrangement and interconnections of the blocksdetermine the function of the Fieldbus devices.

In Step 340, the physical layout of the process control system isapplied to the spatial information regarding the facility layout.Function blocks and devices are wired together, typically following wireframes and the wiring of other devices in the facility. The layout maybe done manually by the user or the tool 120 may automatically generatethe physical layout of the process control system. Information such asthe length of a segment of cable from a controller to a junction or froma junction to another junction and the length of a spur may beautomatically generated and calculated from the spatial layout of therefining or manufacturing facility. In another embodiment, theconnection of the function blocks and devices can first be connectedlogically, and at a later time applied to the spatial informationregarding the facility.

In Step 350, the configuration of the process control system is checkedfor conformance to the requirements of the selected protocol. All of thespur lengths of a segment are checked to assure that the spur lengths donot exceed a predetermined spur length as defined by the standardprotocol. The spur lengths are limited by the number of instruments onthe segment (per segment). I.e., the fewer the number of instruments,the longer the allowable spur length per segment. The number of devicesper segment is also checked to assure that the number of devices do notexceed a predetermined number of devices. The number of devices that areallowed may vary based upon the controller that is used by the processcontrol network. In the preferred embodiment, the controller allows 16devices to be coupled to the bus per segment. However, the presentFieldbus standard allows up to 32 devices to be coupled to the bus persegment. The total current draw per segment is checked to assure thatthe current draw does not exceed the maximum current draw allowed by thestandard protocol. In the preferred embodiment, the maximum current drawallowed is 375 mAmps/segment. The total segment cable length (includingspur length) is checked to assure that the length does not exceed themaximum segment length allowed by the standard protocol. In thepreferred embodiment, the maximum segment length allowed is 6232 feet or1900 meters. The minimum voltage per segment is checked to assure thatthe voltage at any device which is coupled to the process controlnetwork exceeds or equals the voltage set forth by the standardprotocol. In the preferred embodiment, this voltage is 12.5 volts. Ifone or more of the values are not within the limits defined by theprotocol, the user may return to step 340 to revise the configuration ofthe process control network.

Once the process control network has been configured, the user can beginmanaging the process control system, step 360, utilizing the non-spatialand spatial information supplied. For managing field devices, many typesof communication is available, including: obtaining port andcommunication statistics, obtaining status of the field device, viewingand changing resource configuration and parameters, initiating masterreset or self test of the field device, displaying status of the sensorsand changing the sensor upper, lower and zero trim. By providing spatialinformation with the managing communications listed above, the managingfeatures of the process control system are more efficient and easier touse.

The spatial information regarding the facility can be fully threedimensional, including three dimensional walls, devices, workstationsetc. The spatial information regarding the facility may also be a twodimensional blue print of the facility with the configuration of theprocess control system mapped thereon, or any combination of two andthree dimensions as suits the user application.

In other embodiments, the tool may provide the user with a way ofobtaining a bill of materials for the process control network design.The tool may also automatically provide the layout of the processcontrol system within the physical layout of the facility and assurethat the protocol requirements are met.

In another embodiment, the user can configure the system withoutproviding the spatial information of the facility, and at a later timeadd the spatial information for use in the management of the processcontrol system.

It will be appreciated that while functions are described as having acertain order of events, any other order in which the information isprovided or the steps completed is within the scope of the invention.

Referring to FIG. 4, a screen presentation of the configuration portionof the tool using the logical connections of the process control systemare shown in the main control window of the tool 120. The screenrepresentation of tool 120 includes textual pull down menus 402,pictographic menu 404, a stencil portion presentation 406 and a diagramportion screen presentation 408. Stencil items 420 are displayed withinthe stencil portion presentation 406. The user's diagram of the processcontrol environment design is presented in the diagram portion screenpresentation. This diagram of the process control design environment isreferred to as the process control environment view. Each of thepresentations in the main window is re-sizable and relocatable by theuser in accordance with known windowing techniques. The tool 120 tracksthe location and size of the panes of the main window by maintainingpersistent abject data including coordinates within the two-dimensionaldisplay, as well as style and other information.

When designing a process control environment using logical connections,a user simply actuates a stencil item from the stencil portionpresentation 448, drags the actuated stencil item to a desired locationwithin the diagram portion screen presentation 408 and drops theactuated stencil item in a desired location. Control studio objectsystem 130 then creates a diagram item that allows the diagram to createan object with all of the information necessary for configuring aprocess control environment. Because the stencil items are objects whichinclude all of the necessary information for the diagram to configure aprocess control environment, when the process control environment designis completed within the diagram portion, this design may be directlydownloaded to the appropriate portions of the process controlenvironment.

Referring to FIG. 4 and FIGS. 5A–5C, screen presentations of the spatiallayout portion of the tool using spatial information of the facility inthe layout of the process control system are shown. The tool providesfor viewing of different angles and magnifications of the spatial layoutof the process control system. The presentation may be in grayscale orin color. The screen presentations may be included within a window oftool 120 such analogous to the diagram portion screen presentationwindow 408. Other ways of presenting the spatial information are withinthe scope of the invention.

When designing a process control environment using the spatialinformation of the facility, a user starts by either importing thephysical layout of the facility or by creating the layout in the diagramportion of the main control window of the tool 120. To add field devicesor functions, a user simply actuates a stencil item from the stencilportion presentation 408, drags the actuated stencil item to a desiredlocation in the spatial representation of the facility within thediagram portion screen presentation 408 and drops the actuated stencilitem in a desired location. As well as rectangular representations offunctions, the stencil items include three dimensional representationsof items found in a refining or manufacturing facility, such as valves,pumps, tanks, pipes, etc. A spatial portion of the control studio objectsystem 130 then generates a diagram item with the information necessaryfor configuring a process control environment within the spatial layoutof a facility. Because the stencil items are objects which include allof the necessary information for the diagram to configure a processcontrol environment within the spatial layout of a facility, when theprocess control environment design is completed within the diagramportion, this design may be directly downloaded to the appropriateportions of the process control environment including the spatialportion of the control studio object system.

Referring again to FIGS. 5A–5C, examples of a spatial screenpresentation 500 are shown including an example of the physical layoutof the facility in a spatial view. More specifically, FIG. 5A shows apresentation of a physical layout of a facility over a schematic view ofthe facility. The spatial presentation further includes a physical andlogical representation of the various components of the process controlenvironment. Accordingly, a user may advantageously view the physicallocations of the various components of the process control environmentsuperimposed over a schematic view of the facility. FIGS. 5B and 5C showenlarged and rotated views of portions of the diagram presentation ofFIG. 5A. FIGS. 5B–5C thus show examples of how a user can accessportions of the diagram presentation such as that shown in FIG. 5A toobtain a better view of particular portions of the process controlenvironment. It will be appreciated that the spatial presentation neednot necessarily be superimposed over the schematic view.

While the preceding text sets forth a detailed description of numerousdifferent embodiments of the invention, it should be understood that thelegal scope of the invention is defined by the words of the claims setforth at the end of this patent. The detailed description is to beconstrued as exemplary only and does not describe every possibleembodiment of the invention since describing every possible embodimentwould be impractical, if not impossible. Numerous alternativeembodiments could be implemented, using either current technology ortechnology developed after the filing date of this patent, which wouldstill fall within the scope of the claims defining the invention.

OTHER EMBODIMENTS

Other embodiments are within the following claims.

For example, while the protocol in which the preferred embodiment isdescribed analyzes a process control network for a Fieldbus protocol, itwill be appreciated that any protocol may be analyzed by adjusting theappropriate constraints.

Also, for example, while the preferred embodiment operates under aWINDOWS operating system and uses a Wizard type of presentation, it willbe appreciated that these details are not intended to be limiting of theoverall concept of the invention.

Also, while particular embodiments of the present invention have beenshown and described, it will be obvious to those skilled in the art thatchanges and modifications may be made without departing from thisinvention in its broader aspects and, therefore, the appended claims areto encompass within their scope all such changes and modifications asfall within the true spirit and scope of this invention, including butnot limited to implementations in other programming languages.Additionally, while the preferred embodiment is disclosed as a softwareimplementation, it will be appreciated that hardware implementationssuch as application specific integrated circuit implementations are alsowithin the scope of the following claims.

1. A method for configuring and managing a process control network, theprocess control network including a computer having a processor and amemory, the method comprising: providing the computer with informationregarding a spatial layout of a facility; providing the computer withinformation regarding configuration of a plurality of devices within theprocess control network; creating and activating a plurality of functionblocks controlling the plurality of devices; obtaining status of theplurality of devices; and presenting the status of the plurality ofdevices in relation to the spatial layout of the facility.
 2. A methodof claim 1, further comprising analyzing the layout of the processcontrol network in relation to the physical layout of the facility toassure that the layout of the process control network conforms tocriteria of a standard protocol.
 3. A method of claim 2, wherein thestandard protocol is the Fieldbus protocol.
 4. A method of claim 2,wherein the analyzing the layout of the process control system includeschecking spur length of a segment of the process control system.
 5. Amethod of claim 1, further comprising managing the process controlsystem in a run-time environment.
 6. A method of claim 5, wherein themanaging the process control system includes providing a blinking devicerepresentation in a spatial view of the process control system toindicate active alarms.
 7. A method of claim 5, wherein the managing theprocess control system includes initiating master reset or self-test ofthe plurality of devices.
 8. A method of claim 5, wherein the managingthe process control system includes obtaining port and communicationstatistics of the process control system.
 9. A method of claim 5,wherein the spatial layout of the facility is a three-dimensionallayout.
 10. A method of claim 1, wherein the providing a layout of theprocess control network includes automatically generating the layout.11. An apparatus for configuring and managing a process control network,the apparatus comprising: a computer having a processor and a memory;means for providing the computer with information regarding a spatiallayout of a facility; means for providing the computer with informationregarding configuration of a plurality of devices used within theprocess control network; means for creating and activating a pluralityof function blocks controlling the plurality of devices; means forobtaining status of the plurality of devices; and means for presentingthe status of the plurality of devices in relation to the spatial layoutof the facility.
 12. The apparatus of claim 11, further comprising ameans for providing the computer with information regarding materialsused in the process control network.
 13. The apparatus of claim 11,further comprising a tool used to provide a layout of the processcontrol network applied to the spatial layout of the facility.
 14. Theapparatus of claim 13, wherein the tool is used to analyze the layout ofthe process control network applied to the spatial layout of thefacility to assure that the layout of the process control networkconforms to criteria of a standard protocol.
 15. The apparatus of claim14, wherein the standard protocol is the Fieldbus protocol.
 16. Theapparatus of claim 13, further wherein the tool is used for managing theprocess control system in a run-time environment.
 17. The apparatus ofclaim 13, wherein the tool used to provide a layout of the processcontrol network further includes the tool automatically generates thelayout.
 18. The apparatus of claim 13, wherein the tool used formanaging the process control system provides a blinking devicerepresentation in a spatial view of the process control system toindicate active alarms.
 19. The apparatus of claim 13, wherein themanaging the process control system includes obtaining port andcommunication statistics of the process control system.
 20. Theapparatus of claim 13, wherein the spatial layout of the facility is athree-dimensional layout.